System and method for packaging dental ingots

ABSTRACT

A method and system for producing, marking, and packaging ingots for use in fabricating dental prosthetics.

BACKGROUND

1. Field of the Invention

The present disclosure relates to the field of packaging of ingots,particularly those used for dental casting alloys and otherapplications.

2. Background

Several types of alloys are used in dental repair and reconstruction.Typically, these alloys are produced in ingots for convenient handlingand storage in a dental laboratory. As these materials can be expensive,it is important for a dental laboratory to be able to easily monitorinventory, making sure that there is enough on hand to produce dentaldevices, while not maintaining a costly excess.

These alloys can have different compositions for suitability indifferent applications. However, sometimes it is not possible todifferentiate different types of ingots themselves by physicalinspection. Therefore, ingots are usually marked, by engraving, etching,or printing to indicate the alloy of which they are made. It is alsoimportant to keep the various types of ingots organized in the dentallaboratory to facilitate producing dental devices and avoid confusionand potentially costly mistakes by using the incorrect alloy.Additionally, due to the high value of some of the materials and thevalues of some of the alloys provided by various sources of the ingots,methods and systems of identifying the source of and/or composition ofthe materials rapidly can prove valuable.

In addition, counterfeit ingots can enter the market, which can lead toinferior dental products for patients. Sometimes these imitations can bedifficult to discern from the legitimate ingots. Therefore, it is alsoimportant to develop a production system that is difficult to copywithout authorization.

What is needed is a system to efficiently produce and package ingots sothat they can be safely transported and stored, neatly organized, andeasily recognized in a dental laboratory to produce quality dentaldevices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective top view of one embodiment of a tray usedin the present system.

FIG. 1 a depicts a perspective detail view of the tray embodiment shownin FIG. 1.

FIG. 1 b depicts a perspective bottom view of one embodiment of a trayused in the present system.

FIG. 1 c depicts a top planar view of one embodiment of a tray used inthe present system.

FIG. 1 d depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 1.

FIG. 2 depicts a flow chart giving an overview of an embodiment of thepresent system.

FIG. 2 a depicts a detail view of the printing process in one embodimentof the present system

FIG. 3 depicts a flow chart giving an alternate embodiment of thepresent system.

FIG. 4 depicts a flow chart giving an overview of an embodiment of thepackaging process in the present system.

FIG. 5 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 5 a depicts top planar view of the embodiment of a tray used in thepresent system as shown in FIG. 5

FIG. 5 b depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 5.

FIG. 6 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 6 a depicts top planar view of the embodiment of a tray used in thepresent system as shown in FIG. 6.

FIG. 6 b depicts a perspective bottom view of the embodiment of a trayused in the present system as shown in FIG. 6.

FIG. 6 c depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 6.

FIG. 7 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 7 a depicts top planar view of the embodiment of a tray used in thepresent system as shown in FIG. 7.

FIG. 7 b depicts a perspective bottom view of the embodiment of a trayused in the present system as shown in FIG. 7.

FIG. 7 c depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 7.

FIG. 8 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 8 a depicts top planar view of the embodiment of a tray used in thepresent system as shown in FIG. 8.

FIG. 8 b depicts a detail view of the embodiment of a tray used in thepresent system as shown in FIG. 8.

FIG. 8 c depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 8.

FIG. 9 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 9 a depicts top planar view of the embodiment of a tray used in thepresent system as shown in FIG. 9.

FIG. 9 b depicts a detail view of the embodiment of a tray used in thepresent system as shown in FIG. 9.

FIG. 9 c depicts a detail view of the embodiment of a tray used in thepresent system as shown in FIG. 9.

FIG. 9 d depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 9.

FIG. 10 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 10 a depicts top planar view of the embodiment of a tray used inthe present system as shown in FIG. 10.

FIG. 10 b depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 10.

FIG. 10 c depicts a perspective view of another embodiment of the trayshown in FIG. 10.

FIG. 11 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 11 a depicts top planar view of the embodiment of a tray used inthe present system as shown in FIG. 11.

FIG. 11 b depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 11.

FIG. 11 c depicts a perspective view of another embodiment of the trayshown in FIG. 11.

FIG. 12 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 12 a depicts a top planar view of the embodiment of a tray used inthe present system as shown in FIG. 12.

FIG. 12 b depicts a perspective bottom view of the embodiment of a trayused in the present system as shown in FIG. 12.

FIG. 12 c depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 12.

FIG. 12 d depicts a detail view of another embodiment of the tray shownin FIG. 12.

FIG. 12 e depicts a perspective view of another embodiment of the trayshown in FIG. 12.

FIG. 13 depicts a perspective view of another embodiment of a tray usedin the present system.

FIG. 13 a depicts a top planar view of the embodiment of a tray used inthe present system as shown in FIG. 13.

FIG. 13 b depicts a detail transverse cross-sectional view of theembodiment shown in FIG. 13.

FIG. 13 c depicts a detail view of another embodiment of the tray shownin FIG. 13.

FIG. 13 d depicts a detail view of another embodiment of the tray shownin FIG. 13.

DETAILED DESCRIPTION

FIG. 1 depicts a perspective view of one embodiment of a tray 102 thatcan be used in the present system. In some embodiments, a tray 102 cancomprise a retaining surface 104 that can be elevated by a perimeterwall 106 extending substantially perpendicularly and downward from theedges of a retaining surface 104. As shown in FIG. 1, a retainingsurface 104 can have a substantially rectangular geometry with slightlyrounded corners, but in other embodiments can have any other knownand/or convenient geometry.

As shown in the embodiment depicted in FIG. 1, a perimeter wall 106 canhave thickened and/or recessed and/or counter-recessed and/or bulgedand/or convex regions 108 at each corner extending partially along eachadjacent exterior surface of a perimeter wall 106. In some embodiments,an area of a perimeter wall 106 located between thickened regions 108can be marked with text, a logo, or any other desired indicia 110.

In some embodiments, a perimeter wall 106 can extend slightly outwardfrom a retaining surface 104, while thickened regions 108 can have anexterior surface substantially orthogonal to a retaining surface 104. Asshown in FIG. 1, this can create a lip 112 along the top of a thickenedregion 108, slightly below a retaining surface 104.

A retaining surface 104 can further comprise a plurality of cells 114,which, in some embodiments, can each have a geometry so as toselectively engage with a dental alloy ingot. As shown in FIG. 1, a cell114 can have a substantially rectangular longitudinal cross-sectionalgeometry, but in other embodiments can have any other known and/orconvenient geometry. As shown in FIG. 1, a plurality of cells 114 can bearranged adjacently and substantially linearly, but in other embodimentscan have any other known and/or convenient arrangement.

As shown in the embodiment of FIG. 1, cells 114 can be arranged in a 5×6grid pattern with an additional row of 5 cells 114 on each lateral side,which can be staggered relative to the central 5×6 grid of cells 114 toleave substantially square regions at the corners of a retaining surface104. However, in other embodiments, cells 114 can be arranged in anyother known and/or convenient pattern.

In some embodiments, as shown in FIG. 1 a, a cell 114 can have a pair ofsubstantially parallel longitudinal members 116 that can extend downwardfrom a retaining surface 104. A cell 114 can have a pair of end members118 that can extend downward from a retaining surface 104. End members118 can be connected to and substantially orthogonal to a pair ofsubstantially parallel longitudinal members 116 so as to form asubstantially rectangular opening to a cell 114 substantially in theplane of a retaining surface 104. As shown in FIG. 1 a, an end member118 can have a substantially semicircular geometry with the diametersubstantially coinciding with the interior width of a cell 114 and thecurved portion extending downward from a retaining surface 104. In someembodiments, at least one transverse member 120 can extend between andconnect to the lower edges of a pair of substantially parallellongitudinal members 116, having one edge connected along the lowercurve of an end member 118. In some embodiments, a transverse member 120can have a width not exceeding approximately half of the length of acell 114, and each transverse member 120 can have approximately the samewidth. However, in other embodiments, each transverse member 120 canhave a different width. As shown in FIG. 1, in embodiments havingtransverse members 120 each of a width less than approximately half ofthe length of a cell 114, the underside of a cell 114 can remain open topermit access to an ingot from this side.

As shown in FIGS. 1 a and 1 b, a cell 114 can have a substantiallysemi-cylindrical interior cross-sectional geometry. In such embodiments,a substantially cylindrical dental alloy ingot can selectively engagewith a cell 114 such that a longitudinal portion of an ingot remainsabove a retaining surface 104 when occupying a cell 114. However, inother embodiments, a cell 114 can have any other known and/or convenientinterior cross-sectional geometry to selectively engage with a desireddental alloy ingot.

In some embodiments, as shown in FIGS. 1, and 1 a-1 d, at least one tab122 can extend from the top edge of a substantially parallellongitudinal member 116 above a retaining surface 104, and toward theinterior of a cell 114. In some embodiments, as shown in FIG. 1 c, threetabs 122 can extend from the top edge of a substantially parallellongitudinal member 116, such that one tab 122, located substantially atthe midpoint of a substantially parallel longitudinal member 116, canextend over one cell 114, while two flanking tabs 122 can extend over alaterally adjacent cell 114.

As shown in FIG. 1 d, a tab 122 can have an angle of approximately45-degrees, and/or any other known and/or convenient angle whileextending above the top of a retaining surface 104, but in otherembodiments can be positioned at any other known and/or convenientangle. In some embodiments one or more of the tabs 122 can be adaptedand designed to have any desired length and/or flexibility and/orstiffness relative to a longitudinal member 116 and/or any other knownand/or convenient element and/or item. In some embodiments, a tab 122can have a thickness substantially similar to that of a substantiallyparallel longitudinal member 116. In some embodiments, as shown in FIG.1 d, a tab 122 can have a substantially rounded top edge, but in otherembodiments can have any other known and/or convenient geometry. In someembodiments the tab 122 can be thinner than, the same thickness as orthicker than the longitudinal member 116, and/or can have any otherknown and/or convenient and/or desired thickness.

In some embodiments, a tray 102 can be injection molded from copolymerpolypropylene, but in other embodiments can be produced by any otherknown and/or convenient method and with any other known and/orconvenient material. In some embodiments, a material used in forming atray 102 can have any known and/or convenient properties desirable tomeet specified design criteria.

In use, an ingot can be placed horizontally into a cell 114. Inembodiments such as those shown in FIG. 1, in which a cell 114 can beconfigured to hold a substantially cylindrical ingot, end regions ofsaid ingot can rest on transverse members 120. Substantially half of aningot can lie below the top edge of a cell 114, while tabs 122 cansecure an ingot in a cell 114 by extending above the top edge of a cell114 and substantially adjacent to the surface of an ingot lying abovethe top edge of a cell 114. In such embodiments, ingots can remainsecured in cells 114 regardless of the position of a tray 102 (e.g.,upside-down). Further, in such embodiments, portions of the lateralsurface of an ingot can remain accessible via both the top and bottom ofa retaining surface 104.

As a tray 102 is filled, ingots in adjacent cells 114 can apply minimallateral forces to laterally adjacent cells 114. As a result, althoughthe holding force of tabs 122 can vary slightly with the number offilled laterally adjacent cells 114, ingots can be securely held in anyof cells 114 regardless of the number of filled cells 114 versus emptycells 114. As a result, a user can handle a partially filled tray 102without the risk of ingots falling out of cells 114.

To remove an ingot from a tray 102, a user can apply a force directly toan ingot from the underside of the retaining surface 104, through thebottom of a cell 114 between transverse members 120, causing tabs 122 tomomentarily flex away from the lateral centerline of a cell 114 andrelease an ingot.

FIG. 2 is a flow chart depicting an overview of one embodiment of aproduction line of the present system that can comprise the followingsteps. In some embodiments, ingots can be produced by continuous castingor any other known and/or convenient method herein referred to as ingotproduction 200 and stored in any known and/or convenient storage device202. Ingots can be introduced to the system via a first bowl feeder 204or any other known and/or convenient mechanism.

Ingots can be inspected for compliance with required size, mass, weight,cosmetics, or any other known and/or convenient parameters at aninspection station 206. Ingots failing inspection can be transferred toa material reclamation unit 208, where ingots can be reprocessed. Fromthere, ingots can be transferred to an ingot surface refinishing station210, where upon refinishing ingots can be transferred back to a storagedevice 202 and/or they can be returned to the Ingot Production Process200. Ingots passing inspection can then be transferred to a cleaning andpriming station 212, and then enter a second bowl feeder 214 or anyother known and/or convenient mechanism. In some embodiments, an ingotinspection rate can be approximately 80,000 ingots/day (±16,000 . . . ).However, in alternate embodiments any other known and/or convenientrange and/or known and/or convenient and/ordesired±limitation/variation/variance can be implemented.

Ingots can then pass from a second bowl feeder 214 to an ingot-trayinsertion station 216. Trays 102 can be introduced to a tray insertionstation 216 via a stack-feed, linear-feed, or any other known and/orconvenient mechanism. Ingots can then be inserted into trays 102 at arate of approximately 300 trays/hr (±60 . . . ). However, in alternateembodiments, any other known and/or convenient range and/or known and/orconvenient and/or desired±limitation/variation/variance can beimplemented.

Loaded trays 102 can then advance to a weight-check station 218. Loadedtrays can be weighed to check compliance with a desired weight range,which in some embodiments can be 200 gram (±4 grams . . . ) and/or anyother known and/or convenient and/or desired weight range and/or knownand/or convenient and/or desired±limitation/variation/variance. Loadedtrays 102 passing weight inspection can then advance to a first markingstation 220. Loaded trays failing weight inspection can be unloaded andthe ingots returned to either a first bowl feeder 204 or a second bowlfeeder 214.

At a first marking station 220, ingots loaded into a tray 102 can beindividually marked via inkjet printing, pad printing, stamping,engraving, etching, or any other known and/or convenient method. In someembodiments of the present system, a loaded tray 102 can be insertedinto an inkjet printer such that the portion of each ingot's lateralsurface that faces upward and is accessible from the top of a tray 102can be printed with a desired indicia, text, or image. In embodimentsemploying inkjet printing as a marking method, trays can be processed ata rate of 150 trays/hour (±30 . . . ) or any other known and/orconvenient range.

Loaded trays 102 bearing marked ingots can then travel to a secondmarking station 222. Here, the lateral side of an ingot accessible fromthe underside of a retaining surface (i.e., opposite the previouslymarked ingot surface) can be laser marked and/or marked via any otherknown and/or convenient method.

Following marking, loaded trays 102 of ingots can proceed to an opticalinspection station 224. Loaded trays can be inspected at a rate ofapproximately 300 trays/hour (±60 . . . ) or any other known and/orconvenient range. Loaded trays 102 passing optical inspection can thenadvance to a storage device 202 and then final packaging 226. Loadedtrays 102 failing optical inspection can be unloaded and the ingots sentto a reclamation unit 208 for reprocessing. In some embodiments opticalinspection can be performed by a trained person who would make asubjective evaluation/determination of the marks quality based upon apre-approved standard. However, in alternate embodiments, the opticalinspection can be performed by an automated computer based system whichhas been programmed to adhere to a minimum acceptance standard.

FIG. 2 a depicts a flow chart detail of a laser marking/inkjet printingprocess used in one embodiment of the present system. Loaded trays 102can be placed into a laser marking system 228 where they can be markedwith desired indicia, text, or image. In some embodiments, loaded trays102 can then be placed into fixtures 230 which can contain 15 trays(+/−5) and/or any other known and/or convenient number having any knownand/or convenient configuration. In the embodiment depicted in FIG. 2 a,loaded fixtures 232 can then be cleaned and primed via a manual wipingprocess 234 and/or via any other known and/or convenient cleaningprocess. In the embodiment depicted in FIG. 2 a, cleaned and primedloaded fixtures 232 can be placed into the inkjet printing process 236where the ingots can be marked with desired indicia, text, or image. Insome embodiments, upon exiting the inkjet printing process 236, theloaded trays 102 can be removed from the loaded fixture 232 and visuallyinspected 238 for defects. However, the loaded fixture 232 and theingots can be inspected 238 without being removed from the fixture 232.If the tray 102 is deemed acceptable, it can be placed into storage 202and await final packaging 226 and/or can proceed directly to finalpackaging 226. If the tray is deemed unacceptable, the tray 102 can berejected, in-whole or in-part, and can be, in-whole or in-part,submitted to reclaimed material 208 for reprocessing and further ingotproduction 200. In some embodiments, the empty fixture 230 can then bereturned to the beginning of the process.

FIG. 3 depicts a flow chart overview of an alternative embodiment of thepresent system that can comprise the following steps. In someembodiments, ingots can be produced by continuous casting or any otherknown and/or convenient method herein referred to as ingot production300 and stored in any known and/or convenient storage device 302. Ingotscan be introduced to the system via a first bowl feeder 304 or any otherknown and/or convenient mechanism.

Ingots can be inspected for compliance with required size, mass, weight,cosmetics, or any other known and/or convenient parameters at aninspection station 306. Ingots passing inspection can then betransferred to a cleaning and priming station 308, and then enter asecond bowl feeder 310 or any other known and/or convenient mechanism.In some embodiments, an ingot inspection rate can be approximately100,000 ingots/day (±20,000) or any other known and/or convenient rangeand/or known and/or convenient and/ordesired±limitation/variation/variance can be implemented.

Ingots can then pass from a second bowl feeder 310 to an ingot-trayinsertion station 312. Trays 102 can be introduced to a tray insertionstation 312 via a stack-feed, linear-feed, or any other known and/orconvenient mechanism. Ingots can then be inserted into trays 102 at arate of approximately 300 trays/hr (±60) or any other known and/orconvenient range.

Loaded trays 102 can then advance to a weight-check station 314. Loadedtrays can be weighed to check compliance with a desired weight range,which in some embodiments can be 200 grams (±4 grams) and/or any otherknown and/or convenient and/or desired weight range and/or known and/orconvenient and/or desired±limitation/variation/variance. Loaded trays102 passing weight inspection can then advance to a first markingstation 316.

At a first marking station 316, the lateral side of an ingot accessiblefrom the underside of a retaining surface (i.e., opposite the previouslymarked ingot surface) can be laser marked, or marked employing any otherknown and/or convenient marking method and/or system. Laser-markedingots can then be transferred to a second marking station 318.

At a second marking station 318, ingots loaded into a tray 102 can beindividually marked via inkjet printing, pad printing, stamping,engraving, etching, or any other known and/or convenient method. In someembodiments of the present system, a loaded tray 102 can be insertedinto an inkjet printer such that the portion of each ingot's lateralsurface that faces upward and is accessible from the top of a tray 102can be printed with a desired indicia, text, or image. In embodimentsemploying inkjet printing as a marking method, trays can be processed ata rate of 300 trays/hour (±60) or any other known and/or convenientrange and/or known and/or convenient and/ordesired±limitation/variation/variance can be implemented.

Following marking, loaded trays 102 of ingots can proceed to an opticalinspection station 320. Loaded trays can be inspected at a rate ofapproximately 300 trays/hour (±60) or any other known and/or convenientrange and/or known and/or convenient and/ordesired±limitation/variation/variance can be implemented. Loaded trays102 passing optical inspection can then advance to a storage unit 322.

FIG. 4 depicts a flow chart showing an overview of a packaging segmentof an embodiment of the present system. Loaded trays 102 of markedingots can be transferred to an ingot tray storage device 402 to awaitpackaging. In a box machine 404, loaded trays 102 of marked ingots areplaced into pre-folded boxes, which are then sealed around each loadedtray 102. In some embodiments, a box machine can box a loaded tray at arate of approximately 300 packages/hr (±60) or any other known and/orconvenient rate and/or known and/or convenient and/ordesired±limitation/variation/variance can be implemented. In a boxmachine 404, the exterior surface of a sealed box can be marked viaprinting, adhesive label, or any other known and/or convenient method.Such marking can include information relating to dates of manufacture,serialization, lot numbers or any other known and/or convenientinformation relating to production and authentication of the ingotsenclosed.

Sealed boxes can then be transferred to an overwrapping station 406where they can be wrapped with a plastic, cellophane, paper, or anyother known and/or convenient type of overwrapping. Wrapped boxes canthen be transferred to a weight-check station 408. Wrapped individualboxes passing inspection can then be transferred to a master box station410, where individual boxes are grouped and packed into larger units.

At a first master boxing station 410, individual boxes can be placedinto a first master box and then sent to a box sealing station 412.

As shown in FIG. 4, the multiple-pack master boxes can be groupedtogether and sent to a second master boxing station 414 for furtherconsolidation. However, in other embodiments, first master boxes can begrouped into any other known and/or convenient units.

At a second master boxing station 414, individual boxes can be placedinto a second master box and then sent to a final box sealing station416. The larger master boxes can then be sent to a pallet box 418 andgrouped into any known and/or convenient quantity for shipping.

An ancillary benefit of the present system is that it can detercounterfeit activities by creating a production process that can be verydifficult to duplicate. In some embodiments, additional authenticationmeasures can be taken, such as marking with identification andserialization indicia.

In some embodiments, further authentication can be provided by lasermarking and/or marking ingots with a logo, text, or a serial numberusing any known and/or convenient marking method, apparatus and/orsystem. In addition, a tray 102 can also be marked via printing, anadhesive label, or any other known and/or convenient method. A boxenclosing a loaded tray 102, as well as external wrapping on a box canlikewise be marked with such indicia.

In some embodiments the markings can be used to establish authenticityof the ingots. In some embodiments, the individual ingots can be markedwith first indicia, the tray 102 can be marked with a second indicia andthe exterior packaging can be marked with a third indicia. In someembodiments, the first indicia, second indicia and third indicia can berelated in any known and/or convenient manner and/or unrelated and/orrandomized. In some embodiments, the first, second and third indicia canbe used either individually and/or collaboratively to establishauthenticity of the ingots. In alternate embodiments, a user can verifyat least one of the first, second and third indicia to establishauthenticity via communication with an authentication service and/orauthentication method.

FIG. 5 depicts a perspective view of another embodiment of a tray 102that can be used in the present system. In such embodiments, atransverse member 120 can substantially completely enclose the undersideof cell 114.

As shown in FIG. 5, a longitudinal member 116 can have a bilaterallyraised region 502 located substantially at the midpoint of the top edgeof a longitudinal member 116 such that each raised region extends intoadjacent cells 114 sharing a substantially parallel longitudinal member116. As shown in FIG. 5 a, a raised region 502 can extend slightlytoward the longitudinal midline of a cell 114. As shown in FIG. 5 b, thetop edge of a raised region 502, can be coincident with the top of aretaining surface 104 so as not to extend over the top edge of a cell114.

Embodiments such as those depicted in FIG. 5 can be vacuum-formed from apolymer or any other known and/or convenient material. In someembodiments a material can be substantially translucent, but in otherembodiments, can be substantially transparent or opaque. In someembodiments, a material can have any known, convenient and/or desiredstrength and/or flexibility.]

In use, an ingot can be placed into a cell 114 such that raised regions502 can hold the ingot in place. In embodiments such as those shown inFIG. 5, in which a cell 114 can be configured to hold a substantiallycylindrical ingot, an ingot can rest horizontally in a cell 114 suchthat substantially half of an ingot lies below the top edge of a cell114 and raised regions 502 can apply a substantially lateral forceapplied substantially at an ingot's longitudinal midpoint to hold theingot in place. As a tray 102 is filled, ingots in adjacent cells 114can apply lateral forces to laterally adjacent cells 114. As a result,the holding force of raised regions 502 can increase slightly with thenumber of filled laterally adjacent cells 114. However, even if a tray102 is partially filled, sufficient lateral force exists each in cell114 to secure an ingot in place.

To remove an ingot, a user can apply an exterior force directedsubstantially toward the longitudinal midline of an ingot to the bottomsurface of a cell 114, causing a transverse member 120 to deformslightly toward an ingot and substantially parallel longitudinal members116 to momentarily flex laterally outward, increasing the distancebetween raised regions 502 to subsequently release an ingot, as it ispushed upward out of a cell 114.

FIG. 6 depicts a perspective view of another embodiment of a tray 102that can be used in the present system. In some embodiments, as shown inFIG. 6, a pair of laterally adjacent tabs 602 can extend fromsubstantially the midpoint of the top edge of a longitudinal member 116with each extending toward the interior of a laterally adjacent cell114.

As shown in FIG. 6, each laterally adjacent tab 602 can have an angle ofapproximately 45-degrees and/or any other known, convenient and/ordesired angle while extending above the top of a retaining surface 104,but in other embodiments can be positioned at any other known and/orconvenient angle. In some embodiments one or more of the tabs 122 can beadapted and designed to have any desired length and/or flexibilityand/or stiffness relative to a longitudinal member 116 and/or any otherknown and/or convenient element and/or item. In some embodiments, alaterally adjacent tab 602 can have a thickness substantially similar tothat of a substantially parallel longitudinal member 116. In someembodiments, as shown in FIG. 6 c, a laterally adjacent tab 602 can havea substantially rounded top edge, but in other embodiments can have anyother known and/or convenient geometry.

In use, an ingot can be placed horizontally into a cell 114. Inembodiments such as those shown in FIG. 6, in which a cell 114 can beconfigured to hold a substantially cylindrical ingot, end regions ofsaid ingot can rest on transverse members 120. Substantially half of aningot can lie below the top edge of a cell 114, while laterally adjacenttabs 602 can secure an ingot in a cell 114 by extending above the topedge of a cell 114 and substantially adjacent to the surface of aningot, positioned substantially at the transverse midpoint of an ingotlying above the top edge of a cell 114. In such embodiments, ingots canremain secured in cells 114 regardless of the position of a tray 102(e.g., upside-down). Further, in such embodiments portions of thelateral surface of an ingot remain accessible via both the top andbottom of a retaining surface 104.

As a tray 102 is filled, ingots in adjacent cells can apply minimallateral forces to laterally adjacent cells 114. As a result, althoughthe holding force of laterally adjacent tabs 602 can vary slightly withthe number of filled laterally adjacent cells 114, ingots can besecurely held in any of cells 114 regardless of the number of filledcells 114 versus empty cells 114. As a result, a user can handle apartially filled tray without the risk of ingots falling out of cells114.

To remove an ingot from a tray 102, a user can apply a force directly toan ingot from the underside of the retaining surface 104, through thebottom of a cell 114 between transverse members 120, causing laterallyadjacent tabs 602 to momentarily flex away from the lateral centerlineof a cell 114 and release an ingot.

FIG. 7 depicts a perspective view of another embodiment of a tray thatcan be used in the present system. In some embodiments, as shown inFIGS. 7 and 7 a, at least two pairs of laterally adjacent tabs 602 canextend from the top edge of a substantially parallel longitudinal member116 with each extending toward the interior of a laterally adjacent cell114.

As shown in FIG. 7, each laterally adjacent tab 602 can have an angle ofapproximately 45-degrees and/or any other known, convenient and/ordesired angle while extending above the top of a retaining surface 104,but in other embodiments can be positioned at any other known and/orconvenient angle. In some embodiments one or more of the tabs 122 can beadapted and designed to have any desired length and/or flexibilityand/or stiffness relative to a longitudinal member 116 and/or any otherknown and/or convenient element and/or item. In some embodiments, alaterally adjacent tab 602 can have a thickness substantially similar tothat of a substantially parallel longitudinal member 116. In someembodiments, as shown in FIG. 7, a laterally adjacent tab 602 can have asubstantially rounded top edge, but in other embodiments can have anyother known and/or convenient geometry.

In the embodiment shown in FIGS. 7 and 7 b, a transverse member 120 cansubstantially completely enclose the underside of cell 114. As shown inFIG. 7 c, in some embodiments, a transverse member 120 can furthercomprise a thinned section 702 substantially along the longitudinal axisof a transverse member 120. In response to a force, a thinned section702 can deform more easily than the surrounding regions.

In use, an ingot can be placed into a cell 114 such that laterallyadjacent tabs 602 hold an ingot in place. In embodiments such as thoseshown in FIG. 7, in which a cell 114 can be configured to hold asubstantially cylindrical ingot, an ingot can rest in horizontally in acell 114 such that substantially half of an ingot lies below the topedge of a cell 114 and laterally adjacent tabs 602 can slant inward tohold an ingot in place by extending above the top edge of a cell 114 andsubstantially adjacent to the surface of an ingot.

To remove an ingot from the tray, a user can apply a force to a thinnedsection 702 of a transverse member 120, and thereby to an ingot, causinglaterally adjacent tabs 602 to momentarily flex outward and release aningot as a substantially upward force is applied to said ingot.

FIG. 8 depicts a perspective view of another embodiment of a tray thatcan be used in the present system. In some embodiments, a singletransverse member 120 can be located substantially across thelongitudinal midpoint of a cell 114. In some embodiments, a transversemember 120 can have a width not exceeding approximately half of thelength of a cell 114.

In some embodiments, as shown in FIG. 8 a and in more detail in FIG. 8b, at least one end member 118 of a cell 114 can have at least oneprotrusion 802. In some embodiments, a protrusion 802 can be configuredas a curved hook, the curved portion of which can be orientedsubstantially parallel to a retaining surface 104 and can extendlaterally in approximately a ninety-degree arc, or any other knownand/or convenient length. In embodiments having a protrusion 802 onextending from each end member 118, protrusions 802 can be oriented suchthat the free end of each protrusion 802 can extend toward oppositelateral sides of a cell 114.

FIG. 9 depicts a perspective view of another embodiment of a tray 102that can be used in the present system. In some embodiments, at leastone protrusion 802 can be a downward-oriented hook. As shown in FIG. 9,in embodiments having a protrusion 802 at each end of a cell 114, bothprotrusions 602 can be pointed into a cell 114, but in other embodimentscan be pointing opposite directions or in any other known and/orconvenient orientation relative to each other.

FIG. 10 depicts a perspective view of another embodiment of a tray 102that can be used in the present system. In some embodiments, the bottomof a cell 114 can comprise a bottom member 1002 that can extend inwardaround the lower perimeter of a cell 114. End segments 1004 of a bottommember 1002 having a configuration as shown in FIG. 10 can have a widthless than that of half of the length of a cell 114 or any other knownand/or convenient dimension. Lateral segments 1006 can have a width lessthan that of half of the width of a cell 114 or any other known and/orconvenient dimension. In some embodiments, end segments 1004 and lateralsegments 1006 can have different widths, but in other embodiments canhave a uniform width around the perimeter of a base member 1002.

In some embodiments, as shown in FIG. 10, a cell 114 can lack aretaining feature, such as, but not limited to protrusions 802 and tabs122 602. As shown in FIG. 10 c, in such embodiments, a tray 102 canfurther comprise a lid 1008 that can selectively engage with a tray 102to cover a retaining surface 104. In some embodiments, a lid 1008 canselectively engage with a tray 102 by a friction fit, latch system, orany other known and/or convenient mechanism.

FIG. 11 depicts a perspective view of another embodiment of the presentdevice. As shown in FIG. 11, some embodiments can have an upwardextension 1102 of at least two substantially parallel segments of a wall106 above a retaining surface 104. In the embodiment shown in FIG. 11,extensions 1102 can exist of each of the lateral segments and one endsegment of a wall 106. A channel 1104 can be cut into the interiorsurface of an extension 1102, parallel to the top edge of an extension1102 and at a distance from the top of a retaining surface 104 of a tray102 substantially equivalent to slightly more than the radius of aningot, whether cylindrical and/or having any other known and/orconvenient geometry. A lid 1106 can selectively engage with a tray 102via a channel 1104 and hold ingots securely in cells 114.

FIG. 12 depicts a perspective view of another embodiment of a tray 102that can be used in the present system. In some embodiments, as shown inFIG. 12, a cell 114 can comprise both tabs 122 along the top edge of alongitudinal member 116 and protrusions 802 from an end member 118 thatcan serve as retention hooks to hold an ingot in a cell 114.

In some embodiments, an ingot can be inserted from top of the deviceuntil it seats on protrusion 802. In some embodiments, a fixture below(not shown) can help prevent accidental over-insertion. In someembodiments, the fixture below (not shown) may not be present. Onceingot is placed in cell 114, tab 122 can prevent the ingot from fallingout of the top if tray 102 is inverted. In some embodiments, protrusion802 can prevent accidental falling out of the ingots at the bottom.Thus, to eject an Ingot press from the tray 102, a user or machine canpress on top of ingot to pop ingot out of bottom of the tray 102. Insuch embodiments, protrusion 802 can deflect and release the ingot fromthe tray 102.

In alternate embodiments, as shown in FIG. 12 e, a tray 102 can furthercomprise a lid 1008 that can selectively engage with a tray 102 to covera retaining surface 104. In some embodiments, a lid 1008 can selectivelyengage a tray 102 by a friction fit, latch system, or any other knownand/or convenient mechanism.

FIG. 13 depicts a perspective view of another embodiment of a tray 102that can be used in the present system. In some embodiments, a cell 114can further comprise a partial end cap 1302 that can extend over theopen top of a cell 114. As shown in FIG. 13, a partial end cap 1302 canhave an L-shaped configuration and extend from one end of a cell 114. Insome embodiments, the top member of a partial end cap 1302 can beconfigured to selectively engage with an ingot surface. As shown in FIG.13, this can be a curved ingot retention surface to retain asubstantially cylindrical ingot, but in other embodiments can have anyother known and/or convenient geometry.

As shown in FIG. 13, a transverse member 120 can enclose a desiredportion of the bottom of a cell 114, starting at the same end from whicha partial end cap 1302 extends. In some embodiments, a protrusion 802,which can be a downward pointing hook, can extend from the opposite endof a cell 114.

In some embodiments, traverse member 120 is in the mid section of cell114 and connects to the longitudinal members 116 so that the partial endcap 1302 on one end and the protrusion 802 can be formed from theunderside by the injection mold.

In using an embodiment as shown in FIG. 13, an ingot can be placed intoa cell 114 such that one end rests under a partial end cap 1302 and aprotrusion 802 deflects, and the resulting tension in a protrusion 802can help to hold an ingot securely in a cell 114. To release an ingot, auser can press an ingot upward from the underside of a tray via the openportion of the bottom of a cell 114. In some embodiments the user canpress from the underside of the cell 114 at the side of the protrusion802.

Although the method has been described in conjunction with specificembodiments thereof, it is evident that many alternatives, modificationsand variations will be apparent to those skilled in the art.Accordingly, the method as described and hereinafter claimed is intendedto embrace all such alternatives, modifications and variations that fallwithin the spirit and broad scope of the appended claims.

1. A system and method for producing, marking, and packaging ingots,comprising the steps of: introducing ingots to a production line via afirst feeding mechanism; inspecting ingots for conformance to desiredweight, size, and cosmetic requirements; transporting ingots to a secondfeeding mechanism; introducing a plurality of trays into said productionline; inserting ingots into said trays; weighing said filled trays tocheck compliance with a desired weight range; marking said ingots;optically inspecting said ingots; inserting said loaded ingot trays intoa packaging unit; packaging said loaded ingot trays; weighing saidpackaged trays for check compliance with a desired weight range; placinga wrapping on the exterior of a package; sending a wrapped package to amaster packaging station, wherein a plurality of wrapped packages arecombined into a larger unit; placing a wrapping on the exterior of alarger unit; combining a plurality of larger units into a pallet box forshipping.
 2. The system of claim 1, wherein said marking is accomplishedby a method selected from the list consisting of: inkjet printing, padprinting, stamping, etching, and engraving.
 3. The system of claim 1,wherein a tray further comprises: a base member having a vertical wallextending substantially perpendicularly downward from the perimeter of asubstantially planar member; a plurality of adjacent openings in saidsubstantially planar member, each opening connected to at least onebottom member to form a compartment, and each compartment separated by alateral wall.
 4. The tray of claim 3, wherein compartment has asubstantially semicircular cross-section.
 5. The tray of claim 3,wherein said compartment has a substantially open bottom.
 6. The tray ofclaim 5, further comprising a plurality of tabs extending from the topedge of said lateral compartment walls.
 7. The tray of claim 6, whereinsaid tabs are configured with three tabs extending from each lateralcompartment wall, alternately such that two tabs extend slightly overthe lateral edge of one compartment, while the third tab, between thefirst two tabs, extends slightly over the adjacent lateral edge of alaterally adjacent compartment.
 8. The tray of claim 6, wherein a pairof adjacent tabs extend from substantially the middle portion of alateral compartment wall, each tab extending over the adjacent lateraledge of a laterally adjacent compartment.
 9. The tray of claim 8 ,wherein said tabs extend upward at an angle of approximately 45 degreeswith respect to a top surface.
 10. The tray of claim 5, wherein saidcompartment further comprises at least one protrusion extending into acompartment from and end surface of said compartment.
 11. The tray ofclaim 10, wherein said protrusion is a hook oriented concave down withrespect to the end of a compartment from which a protrusion extends. 12.The tray of claim 5, further comprising an L-shaped partial end capextending substantially perpendicularly from a top surface of a tray andover the open top of a compartment.
 13. The tray of claim 3, wherein thelongitudinal median section of a bottom member is more easily deformablethan the remainder of a bottom member.
 14. The tray of claim 3 or 5,further comprising a lid capable of selectively engaging with said basemember.